INTEGRATED CABLE SOLUTIONS FOR OFFSHORE WIND DEVELOPMENT OFFSHORE WIND BRINGS NEW OPPORTUNITIES Offshore wind is one of the most stable New industry trends and drivers sources of renewable energy. Power • Increased cost-competitiveness: Offshore wind power fluctuations are minimal due to prevalent solutions are getting less and less expensive ocean wind patterns. And the need for • Larger and more efficient turbines: Higher energy standby generator capacity for peak load capture, increased reliability and lower operating and servicing is largely eliminated through maintenance costs can generate considerable savings accurate weather forecasting combined with per unit. Next-generation12-15 MW turbines requires remote databased control and management. durable, large capacity cables This reduces costs, enhances network stability, and contributes to a balanced clean • Deeper waters farther out to sea: Offshore towers and power supply. infrastructure must be able to handle severe ocean conditions. Cables and components need to be salt- and water-resistant and display dynamic maritime In the near future, installed offshore wind production qualities capacity is expected to increase from 20 GW today up to 150 GW by 2030, thus becoming a trustworthy • Upgraded transmission and interconnection renewable resource for Europe’s integrated supergrids infrastructure: Ocean-based turbines, whether fullscale of the future. Indeed, offshore wind is deemed to play a floating devices or grounded on the seabed, require key role in “keeping global warming below 2° C,” the appropriate infrastructure to export energy to land-based objective of the Paris Agreement 2018. grids, and provide telecommunications for remote control Recent offshore wind trends include a move towards larger • Improved supply chain, logistics and installation: turbines and deep-water floating units. Offshore projects Optimization could potentially achieve 3 % savings. (up to 200 km from shore) require robust cables, precise This demands cable and accessories availability, as maritime installation, as well as efficient long-distance well as onsite delivery and installation using specialized transmission, involving innovative cable solutions and cable laying vessels. This requires marine proficiency reliable accessories. and cable-laying capability • Partnerships and trans-regional cooperation: This is especially crucial in research, technological development and training. International projects require specialized cable expertise, shared knowhow, and adherence to world standards INTEGRATING CABLES AND POWER ACCESSORIES IN TOUGH SEA CONDITIONS INTEGRATING CABLES AND POWER ACCESSORIES IN TOUGH SEA CONDITIONS Nexans has the expertise to outfit large offshore wind turbines, interconnect them in complete windfarms, and link them to distant or local or grids. For medium and high- voltage cables, Nexans oversee complete installation, from initial pre-qualification, design, customized production, logistics, installation, testing and pre-commissioning. This includes all accessories, a key element in any efficient energy network. Nexans supply and lay MV subsea cables between wind turbines and the transformer platform, and the MV or HV link to the onshore substation. Nexans also provide power accessories and topside termination on wind turbines and transformer platforms. At the same time, we have been developing cables and power accessories for those OEMs producing a new generation of stationary and floating turbines. Apart from a full range of energy cables and services, Nexans is also an expert in the telecommunications infrastructure needed to manage offshore wind parks, including control and data cables, copper and fiber Local Area Networks. Innovative technologies • World supplier of submarine and underground cables, overhead conductors and data/telecom systems • Close partnership with developers, power utilities, installers and contractors • Mastery of maritime conditions based on oil & gas submarine energy and telecom cabling experience • Unsurpassed offshore installation and topside termination experience using advanced equipment, special software for overhead lines, and dynamic cable solutions • Complete range of power accessories: separable outer- cone T-connectors, bushings, surge-arresters, cold-shrinkable and heat-shrinkable joints and terminations for various types of cables • A wide range of aluminum based solutions, mechanical connectors, cable lugs and pre-manufactured cable kits for offshore wind turbine manufacturers, ensuring reliable aluminum to copper connectivity • System solutions in the transition piece where junction frames or cabinets assure the link between an inter array cable and the switch in the basement of a tower. This ensures easy and effective mounting and a clear responsibility border during build-up of the tower PRE-TERMINATED TURBINE CABLE SOLUTIONS Nexans WINDLINK® offer proposes a full range of reliable, high-performance cable solutions for wind turbines. WINDLINK® contributes to improve wind turbine output and performance and comprises solutions for both towers and nacelles. Fully tested electrical systems and easy-to- install kits considerably reduce installation time. Some of the main product families include: Low-voltage loop rubber cables (EPR cable class 5) Low-voltage fixed installation cables • These cables (up to 1 kV) reliably transmit energy • Copper can be single or multicore, with produced in the generator to the transformer EMC screening • They come in Low-Smoke Zero-Halogen (LSZH) versions, • Aluminium single core are larger but cheaper; their and are also oil-, abrasion-, UV- and ozone resistant lightness make them easier to handle and install in towers > Whenever Nexans supplies this type of cable, lifetime > Nexans has supplied a wide range of LV installation tests according to movement and torsion requirements cables to Alstom Wind, Nordex, Siemens, Vestas, are performed. GE, etc Low-voltage loop aluminum cables Low-voltage joints and accessories • Nexans systems use • Innovative cable design to allow torsion requirements mechanical shear-off- head due to nacelle rotation bolt connector with an • 150 mm2 to 400 mm2 aluminum replaces 95 mm2 to innovative rubber sleeve 240 mm2 copper which enable them to • Mechanical connectors with shear-off-head bolts tolerate withstand thermal cycling and different conductor cross-sections. The force of the screw tower vibration throughout the creates electrical contact between the conductor and turbine lifetime connector body • A new connector made of high-strength aluminum alloy • Factory pre-installed solutions, including cables, lugs (copper to aluminum) with a protective roll-on sleeve is fast and connectors and easy to install without special tools > Roll-on sleeves offer protection, insulation, short-circuit Medium-voltage loop rubber cables stability and long-term reliability Low-voltage kits • To facilitate assembly, Nexans provides pre- terminated kits which bundle energy, control and data cables for wind turbine electronics • Also, cut-to-length, pre-connectorized, all-power cables are supplied to tower manufacturers for generator-to- switchgear-to-main-powerline links • Similar to LV loop cables, they can handle up to 66 kV between the transformer and the switchgear at the base A full range of WINDLINK® rubber cables. > We are delivering MV loop cables in 3+1 core or 3+3 core designs to all the major WTG manufacturers using this solution MV accessories designed to reduce Medium-voltage connectors installation time • Nexans safe-to-touch T-shaped standard outer cone connectors are designed for the new generation of compact switchgears and transformers • Power accessories can also accommodate larger cross-sections up to 1 200 mm² of large turbines and cable-to-cable connections up to 66 kV (Umax=72,5kV), all in an outer cone version > The compact design makes it easy to connect to the transformer’s three phases without female units Auxiliary equipment and systems • A range of offshore junction cabinets (OJC) or frames (OJF) for use in the transition piece of turbine towers and Mechanical support (hang- in substations. Pre-terminated leads offer important off and clamping systems, cost savings protective shells ⁄ slabs ⁄ mattresses) • For offshore, an OJC can be used as a connectionpoint between tower cables and subsea array cables > Easy-to-install hang-offs to fasten energy cables above • Cabinets and frames can also be used in offshore sea level, available sealed substation solutions or non-sealed > Our terminations and joints make installation quick, easy and long lasting. Specific training courses in power accessories installation are available SUBSEA CABLE SOLUTIONS Medium-voltage cables 66 kV Power Accessories • Cost-efficient submarine 3-core cables with integrated fiber optic With the development of the 66 elements and customized armor kV inter-array cable, the full range designs up to 66 kV voltage level of bushings, connectors, surge arresters, terminations, joints and > Nexans has provided the world’s special alloy contacts for large first 66 kV inter-array for the Blyth cross-sections were developed. Offshore Demonstrator Windfarm The connectors are based on the High-voltage export cables outer cone standard and the piggy-back principle. Besides the easy mounting conditions of a plug- • Offshore HVAC transmission: in connector, they are also easy to use in an submarine cables ranging from environment of 2 or more cables for one phase. 123 kV to 420 kV with various